Substrate with a superhard coating containing boron and nitrogen and method of making the same

Abstract

A cutting tool includes a substrate and a coating on the substrate. The coating includes a base adhesion layer that is on at least a portion of the substrate. A first intermediate adhesion layer, which includes boron and a first element, that is on the base adhesion layer. A second intermediate adhesion layer, which includes boron, the first element, and nitrogen, that is on the first intermediate adhesion layer. An outer adhesion layer, which includes boron and nitrogen preferably in the form of cubic boron nitride, that is on the second intermediate adhesion layer. A wear coating scheme wherein the innermost layer of the wear coating scheme is on the outer adhesion layer.

What is claimed is: 
     
       1. A substrate with a coating on at least a part thereof, the coating comprising: a base adhesion layer, the base adhesion layer being on at least a portion of the substrate;   a first intermediate adhesion layer not containing nitrogen and including boron and a first element, the first intermediate adhesion layer being on the base adhesion layer;   a second intermediate adhesion layer including boron, the first element, and nitrogen, the second intermediate adhesion layer being on the first intermediate adhesion layer;   an outer adhesion layer including boron and nitrogen, the outer adhesion layer being on the second intermediate adhesion layer; and   a wear coating scheme, an innermost layer of the wear coating scheme being on the outer adhesion layer.   
     
     
       2. A substrate according to claim 1 wherein the base adhesion layer includes a reactive metal, the reactive metal selected from the group consisting of titanium, zirconium, hafnium, magnesium, and aluminum, and the first element is carbon. 
     
     
       3. A substrate according to claim 1 wherein the wear coating scheme comprises a base wear layer on the outer adhesion layer. 
     
     
       4. A substrate according to claim 3 wherein the wear coating scheme further includes an outer wear layer on the base wear layer. 
     
     
       5. A substrate according to claim 1 wherein the first element comprises carbon. 
     
     
       6. A substrate according to claim 4 wherein the first element comprises carbon; the base wear layer comprises boron, nitrogen, and carbon; and the outer wear layer comprises boron and nitrogen. 
     
     
       7. A substrate according to claim 1 wherein the first intermediate adhesion layer and the second intermediate layer have at least one element in common. 
     
     
       8. A substrate according to claim 1 wherein the second intermediate adhesion layer and the outer adhesion layer have at least one element in common. 
     
     
       9. A substrate according to claim 1 wherein the first intermediate adhesion layer, the second intermediate layer and the outer adhesion layer have at least element in common. 
     
     
       10. A substrate according to claim 4 wherein the outer wear layer comprises boron nitride. 
     
     
       11. A substrate according to claim 4 wherein the outer wear layer comprises cubic boron nitride. 
     
     
       12. A tooling substrate with a coating on at least a part thereof, the coating comprising: a base adhesion layer, the base adhesion layer being on at least a portion of the tooling substrate;   a first intermediate adhesion layer not containing nitrogen and including boron and a first element, the first intermediate adhesion layer being on the base adhesion layer;   a second intermediate adhesion layer including boron, the first element, and nitrogen, the second intermediate adhesion layer being on the first intermediate adhesion layer;   an outer adhesion layer including boron and nitrogen, the outer adhesion layer being on the second intermediate adhesion layer; and   a wear coating scheme, an innermost layer of the wear coating scheme being on the outer adhesion layer.   
     
     
       13. A tooling substrate according to claim 12 wherein the base adhesion layer includes a reactive metal, the reactive metal selected from the group consisting of titanium, zirconium, hafnium, magnesium, and aluminum, and the first element is carbon. 
     
     
       14. A tooling substrate according to claim 12 wherein the wear coating scheme comprises a base wear layer on the outer adhesion layer. 
     
     
       15. A tooling substrate according to claim 14 wherein the wear coating scheme further includes an outer wear layer on the base wear layer. 
     
     
       16. A substrate according to claim 12 wherein the first element comprises carbon. 
     
     
       17. A tooling substrate according to claim 15 wherein the first element comprises carbon; the base wear layer comprises boron, nitrogen, and carbon; and the outer wear layer comprises boron and nitrogen. 
     
     
       18. A tooling substrate according to claim 12 wherein the first intermediate adhesion layer and the second intermediate layer have at least one element in common. 
     
     
       19. A tooling substrate according to claim 12 wherein the second intermediate adhesion layer and the outer adhesion layer have at least one element in common. 
     
     
       20. A tooling substrate according to claim 12 wherein the first intermediate adhesion layer, the second intermediate layer and the outer adhesion layer have at least element in common. 
     
     
       21. A tooling substrate according to claim 12 wherein the tooling substrate comprises a tip for use in one of a mining tool, a construction tool, an earth drilling tool, and a rock drilling tool. 
     
     
       22. A tooling substrate according to claim 12 wherein the tooling substrate comprises a substrate for use in one of drilling, turning, and milling. 
     
     
       23. A tooling substrate according to claim 12 wherein the tooling substrate comprises an insert for use in one of drilling, turning, and milling. 
     
     
       24. A tooling substrate according to claim 23 wherein the insert comprises an indexable insert. 
     
     
       25. A tooling substrate according to claim 12 wherein the tooling substrate comprises a metal. 
     
     
       26. A tooling substrate according to claim 12 wherein the tooling substrate comprises a composite. 
     
     
       27. A tooling substrate according to claim 26 wherein the composite comprises a cemented carbide. 
     
     
       28. A tooling substrate according to claim 27 wherein the cemented carbide comprises a cemented carbide having an enrichment of binder near a surface of the tooling substrate. 
     
     
       29. A tooling substrate according to claim 27 wherein the cemented carbide comprises a cobalt cemented tungsten carbide. 
     
     
       30. A tooling substrate according to claim 26 wherein the composite comprises a cermet. 
     
     
       31. A tool substrate according to claim 12 wherein the tooling substrate comprises a ceramic. 
     
     
       32. A tooling substrate according to claim 12 wherein the wear coating scheme has a thickness sufficient to withstand turning of a hardened alloy. 
     
     
       33. A tooling substrate according to claim 12 wherein the wear coating scheme has a thickness sufficient to withstand turning a ferrous alloy. 
     
     
       34. A tooling substrate according to claim 12 wherein the wear coating scheme has a sufficient thickness to withstand turning a hardened steel. 
     
     
       35. A tooling substrate according to claim 12 wherein the coating scheme has a thickness comprising at least about 1 micrometer. 
     
     
       36. A tooling substrate according to claim 12 wherein the coating scheme has a thickness comprising at least about 3 micrometers. 
     
     
       37. A tooling substrate according to claim 12 wherein the coating scheme has a thickness comprising up to about 5 micrometers. 
     
     
       38. A tooling substrate according to claim 15 wherein the outer layer of the wear coating scheme comprising boron and nitrogen. 
     
     
       39. A tooling substrate according to claim 15 wherein the outer layer of the wear coating scheme comprising boron nitride. 
     
     
       40. A tooling substrate according to claim 15 wherein the outer wear layer of the wear coating scheme comprising cubic boron nitride. 
     
     
       41. A tooling substrate with a coating thereon, the coating comprising: a base adhesion layer, the base adhesion layer being on at least a portion of the tooling, substrate;   a first intermediate adhesion layer not containing nitrogen and including boron and a first element, the first intermediate adhesion layer being on the base adhesion layer;   a second intermediate adhesion layer including boron, the first element, and nitrogen, the second intermediate adhesion layer being on the first intermediate adhesion layer;   an outer adhesion layer including boron and nitrogen, the outer adhesion layer being on the second intermediate adhesion layer; and   a sequence of a basic wear coating scheme, an innermost layer of the sequence being on the outer adhesion layer.   
     
     
       42. A tooling substrate according to claim 41 wherein the base adhesion layer includes a reactive metal, the reactive metal selected from the group consisting of titanium, zirconium, hafnium, magnesium, and aluminum, and the first element is carbon. 
     
     
       43. A tooling substrate according to claim 41 wherein the base adhesion layer includes titanium. 
     
     
       44. A tooling substrate according to claim 41 wherein the base coating scheme comprises a base wear layer and the base wear layer of a first sequence is on the outer adhesion layer. 
     
     
       45. A tooling substrate according to claim 44 wherein the base wear coating scheme further includes an outer wear layer on the base wear layer. 
     
     
       46. A tooling substrate according to claim 45 wherein the base wear layer of a second sequence is on the outer wear layer of the first sequence. 
     
     
       47. A tooling substrate according to claim 46 wherein the base wear layer of the first sequence and the wear layer of the second sequence are substantially the same and the first element comprises carbon. 
     
     
       48. A tooling substrate according to claim 47 wherein the outer wear layer of the first sequence and the outer wear layer second sequence are substantially the same and the first element comprises carbon; the base wear layer comprises boron, nitrogen, and carbon; and the outer wear layers comprises boron and nitrogen. 
     
     
       49. A tooling substrate according to claim 48 wherein the outer wear layer comprises boron nitride. 
     
     
       50. A tooling substrate according to claim 48 wherein the outer wear layer comprises cubic boron nitride. 
     
     
       51. A tooling substrate according to claim 41 wherein the first intermediate adhesion layer and the second intermediate layer have at least one element in common. 
     
     
       52. A tooling substrate according to claim 41 wherein the second intermediate adhesion layer and the outer adhesion layer have at least one element in common. 
     
     
       53. A tooling substrate according to claim 41 wherein the first intermediate adhesion layer, the second intermediate layer and the outer adhesion layer have at least element in common. 
     
     
       54. A tooling substrate according to claim 41 wherein the tooling substrate comprises a tip for use in one of a mining tool, a construction tool, an earth drilling tool, and a rock drilling tool. 
     
     
       55. A tooling substrate according to claim 41 wherein the tooling substrate comprise a substrate for use in one of drilling, turning, and milling. 
     
     
       56. A tooling substrate according to claim 41 wherein the tooling substrate comprise a insert for use in one of drilling, turning, and milling. 
     
     
       57. A tooling substrate according to claim 56 wherein the insert comprises an indexable insert. 
     
     
       58. A tooling substrate according to claim 41 wherein the tooling substrate comprises a metal. 
     
     
       59. A tooling substrate according to claim 41 wherein the tooling substrate comprises a composite. 
     
     
       60. A tooling substrate according to claim 59 wherein the composite comprises a cemented carbide. 
     
     
       61. A tooling substrate according to claim 60 wherein the cemented carbide comprises a cemented carbide having an enrichment of binder near a surface of the tooling substrate. 
     
     
       62. A tooling substrate according to claim 60 wherein the cemented carbide comprises a cobalt cemented tungsten carbide. 
     
     
       63. A tooling substrate according to claim 59 wherein the composite comprises a cermet. 
     
     
       64. A tool substrate according to claim 41 wherein the tooling substrate comprises a ceramic. 
     
     
       65. A tooling substrate according to claim 41 wherein the sequence of the basic wear coating layer has a thickness sufficient to withstand turning of a hardened alloy. 
     
     
       66. A tooling substrate according to claim 41 wherein the sequence of the basic wear coating has a thickness sufficient to withstand turning of a ferrous alloy. 
     
     
       67. A tooling substrate according to claim 41 wherein the sequence of the basic wear coating has a thickness sufficient to withstand turning of a hardened steel. 
     
     
       68. A tooling substrate according to claim 41 wherein the coating has a thickness comprising at least about 1 micrometer. 
     
     
       69. A tooling substrate according to claim 41 wherein the coating has a thickness comprising at least about 3 micrometers. 
     
     
       70. A tooling substrate according to claim 41 wherein the coating has a thickness comprising up to about 5 micrometers. 
     
     
       71. A tooling substrate according to claim 45 wherein the outer wear layer comprises boron nitride. 
     
     
       72. A tooling substrate according to claim 45 wherein the outer wear layer comprises cubic boron nitride. 
     
     
       73. A tooling substrate according to claim 41 wherein a first intermediate adhesion layer has a thickness of about 10 Å to about 10,000 Å the second intermediate adhesion layer having a thickness of about 10 Å to about 10,000 Å and the outer adhesion layer has a thickness of about 10 Å to about 20,000 Å.